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SERIES 60 Cylinder Block Liner Boring

ADDITIONAL INFORMATION

SHOP NOTES

Shop notes contains information on checking bearing clearances, the crankshaft remanufacturing procedures and a glossary. ‪

Further information will be printed as it is developed. ‪

A strip of soft plastic squeezed between the crankshaft journal and the connecting rod bearing or main bearing may be used to measure the bearing clearances. ‪

The strip is a specially molded plastic "wire manufactured commercially and is available in three sizes and colors. Type PG-1 (green) has a clearance range of 0.0254-0.0762 mm (0.001 -0.003 in.). Type PR-1 (red) has a range of 0.0508-0.1524 mm (0.002 -0.006 in.). Type PB-1 (blue) has a range of 0.1016-0.2286 mm (0.004 -0.009 in.). ‪

The plastic strip may be used for checking the bearing clearances as follows: ‪

  1. Remove the bearing cap and wipe the oil from the bearing shell and the crankshaft journal to be checked.

    Note: Check the main bearing clearances with the weight of the crankshaft supported by a jack under the counterweight adjoining the bearing being checked. If the engine is positioned with the main bearing caps supporting the crankshaft and flywheel, an erroneous reading could result.

  2. Place a piece of plastic strip the full width of the bearing shell, about 1/4 inch off center. See Figure 20323 .

    Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance

  3. Install the bearing cap. Torque the bolts to 470-530 Nm (347-391 lbft).
  4. Remove the bearing cap. The flattened plastic strip will be found adhering to either the bearing shell or the crankshaft.
  5. Compare the width of the flattened plastic strip at its widest point with the graduations on the envelope. See Figure 20323 . The value within the graduation on the envelope indicates the bearing clearance in thousands of an inch. To obtain metric specifications:
    1. Multiply the reading obtained (in thousandths) by 25.4. Taper may be indicated when one end of the flattened plastic strip is wider than the other.
    2. Measure each end of the plastic strip. The difference between the two readings is the approximate amount of taper.

CRANKSHAFT REMANUFACTURING PROCEDURES

This section describes the procedures used to remanufacture crankshafts. ‪

In addition to the standard size main and connecting rod bearings, 0.254 mm, 0.508 mm and 0.762 mm (approximately 0.010 in., 0.020 in., and 0.030 in.), underseas bearings listed in Table are available. ‪

Crankshafts which exhibit surface irregularities may be reground to utilize these bearings. Listed in Table , are guidelines to determine if the crankshaft is suitable for regrinding: ‪

Bearing Size

11 & 12L Connecting Rod Journal Diameter

14L Connecting Rod Journal Diameter

Main Bearing Journal Diameter

Standard ‪

85.000 - 84.975 mm (3.346 in. - 3.345 in.) ‪

95.000 - 94.975 mm (3.740 in. - 3.739 in.) ‪

125.000 - 124.975 mm (4.921 in. - 4.920 in.) ‪

0.254 mm (0.010 in.) Undersize ‪

*84.750 - 84.775 mm (3.336 in. - 3.337 in.) ‪

94.750 - 94.775 mm (3.730 in. - 3.731 in.) ‪

*124.750 - 124.725 mm (4.911 in. - 4.910 in.) ‪

0.508 mm (0.020 in.) Undersize ‪

*84.500 - 84.475 mm (3.327 in. - 3.326 in.) ‪

94.500 - 94.475 mm (3.720 in. - 3.719 in.) ‪

*124.500 - 124.475 mm (4.902 in. - 4.901 in.) ‪

0.762 mm (0.030 in.) Undersize ‪

*84.250 - 84.225 mm (3.317 in. - 3.316 in.) ‪

94.250 - 94.225 mm (3.711 in. - 3.709 in.) ‪

*124.250 - 124.225 mm (4.892 in. - 4.891 in.) ‪

Crankshaft Journal Specifications

Note: * Dimension of reground crankshaft.

Perform the following steps for part inspection: ‪

  1. Determine if the crankshaft is from an 11.1 liter engine or a 12.7 liter engine. Listed in Table are the forging number history for Series 60 crankshafts.

    Model

    Series 60 Crankshaft

    Forging Part Number

    Part Number History

    Year Released

    Fillet Finishing

    11.1 Liter ‪

    8929238 ‪

    1986 ‪

    Induction Hardened ‪

    12.7 Liter ‪

    8929239 ‪

    1986 ‪

    Induction Hardened ‪

    14 Liter ‪

    23522887 ‪

    1998 ‪

    Induction Hardened ‪

    Crankshaft Part Number History
  2. Inspect connecting rod and main bearing journals for discoloration due to excessive overheating from bearing failure.

    Note: Crankshafts with discoloration are not acceptable for rework.

  3. Inspect keyway conditions using width gages and micrometers. Compare with the specifications. See Figure 20324 .

    Standard Crankshaft Keyway Dimensions

  4. Inspect flange bolt holes visually and determine if any necessary repairs can be made by chasing threads or installing heli-coil(s).
  5. Regardless of seal area wear condition, a new sleeve and seal must be installed.
  6. Read and record all "bearing" total indicator reading (TIR) measurements with the crankshaft mounted in vee blocks. Listed in Table are TIR limits.

    Note: Run-out tolerance listed in Table are given for guidance when regrinding crankshaft. When the run-out on adjacent journals is in the opposite direction, the sum must not exceed 0.076 mm (0.003 in.) total indicator reading. When the run-out on adjacent journals is in the same direction, the difference must not exceed 0.076 mm (0.003 in.) total indicator reading.

    Journals Supported On

    Journals Measured

    Maximum Run-Out (Total Indicator Reading)

    No. 1 and No. 7 ‪

    No. 2 and No. 6 ‪

    0.076 mm (0.003 in.) ‪

    No. 1 and No. 7 ‪

    No. 3 and No. 5 ‪

    0.127 mm (0.005 in.) ‪

    No. 1 and No. 7 ‪

    No. 4 ‪

    0.152 mm (0.006 in.) ‪

    Bearing Total Indicator Reading (TIR) Specifications
  7. Whether run-out on adjacent journals is in the same or opposite directions, the sum shall not exceed 0.076 mm (0.003 in.) TIR.
  8. When high spots of run-out adjacent journals are at right angles to each other, the sum shall not exceed 0.10 mm (0.004 in.) TIR or 0.05 mm (0.002 in.) on each journal.
  9. In the event of bearing seizure, bearing overlay must be removed. Check the width of journals to determine whether the sidewalls can be reground. See Figure 20325 for location of crankshaft dimensions. Crankshaft specifications are listed in Table .

    Standard Crankshaft Dimensions

    Location

    Diameter, mm (in.)

    A ‪

    11.1 L 132.970-133.000 mm (5.235-5.236 in.) ‪

    12.7 L 133.670-133.770 mm (5.263-5.264 in.) ‪

    B ‪

    80.19-80.22 mm (3.157-3.158 in.) ‪

    C ‪

    131.72-131.78 mm (5.185-5.188 in.) ‪

    D ‪

    49.35-49.65 mm (1.943-1.955 in.) ‪

    E (11 & 12 L) ‪

    84.975-85.000 mm (3.345-3.346 in.) ‪

    E (14 L) ‪

    94.975-95.000 mm (3.742-3.743 in.) ‪

    F ‪

    49.45-49.55 mm (1.947-1.950 in.) ‪

    G ‪

    131.72-131.78 mm (5.186-5.188 in.) ‪

    H ‪

    55.77-56.07 mm (2.196-2.208 in.) ‪

    Crankshaft Specifications
  10. Visually inspect the entire crankshaft for any serious deviations from normal wear patterns, cracks, nicks or other damage.
  11. If the crankshaft has been ground undersize prior to present receiving inspection, check fillets, thrust, and all widths to determine whether or not enough stock remains to warrant regrinding. See Figure 20325 for location of crankshaft dimensions. Listed in Table are crankshaft remanufacturing tolerances.

    Crankshaft Specifications

    Minimum

    Maximum

    Tolerance

    Journal Diameter - Main Bearing ‪

    124.975 mm (4.920 in.) ‪

    125.000 mm (4.921 in.) ‪

    0.025 mm (0.001 in.) ‪

    Journal Diameter - Connecting Rod Bearing ‪

    84.975 mm (3.345 in.) ‪

    85.000 mm (3.346 in.) ‪

    0.025 mm (0.001 in.) ‪

    14L Journal Diameter - Connecting Rod Bearing ‪

    94.975 mm (3.742 in.) ‪

    95.000 mm (3.743 in.) ‪

    0.025 mm (0.001 in.) ‪

    Journal Out-of-Round - Main Bearing ‪

    - ‪

    0.015 mm (0.0006 in.) ‪

    0.015 mm (0.0006 in.) ‪

    Journal Out-of-Round - Connecting Rod Bearing ‪

    - ‪

    0.010 mm (0.0004 in.) ‪

    0.010 mm (0.0004 in.) ‪

    Journal Taper - Main Bearing - Full Length ‪

    - ‪

    0.013 mm (0.0005 in.) ‪

    0.013 mm (0.0005 in.) ‪

    Journal Taper - Connecting Rod - Full Length ‪

    - ‪

    0.010 mm (0.0004 in.) ‪

    0.010 mm (0.0004 in.) ‪

    Journal Taper Connecting Rod Half - Length ‪

    - ‪

    0.005 mm (0.0002 in.) ‪

    0.005 mm (0.0002 in.) ‪

    Gear Fit Run-out TIR (Total Indicated Reading) ‪

    - ‪

    0.030 mm (0.0012 in.) ‪

    0.030 mm (0.0012 in.) ‪

    Journal Alignment - Main and Connecting Rod - Per Length of Pin ‪

    - ‪

    0.012 mm (0.0005 in.) ‪

    0.012 mm (0.0005 in.) ‪

    Axial Profile Slope - Main - Full Length ‪

    - ‪

    0.008 mm (0.0003 in.) ‪

    0.008 mm (0.0003 in.) ‪

    Axial Profile Slope - Mains Per 5.0 mm (0.197 in.) of Length ‪

    - ‪

    0.006 mm (0.00024 in.) ‪

    0.006 mm (0.00024 in.) ‪

    Axial Profile Slope - Connecting Rod Journals - Full Length ‪

    - ‪

    0.006 mm (0.0002 in.) ‪

    - ‪

    Axial Profile Slope - Connecting Rod Journals - Per 5.0 mm (0.197 in.) of Length ‪

    - ‪

    0.003 mm (0.0001 in.) ‪

    - ‪

    Main and Connecting Rod Fillet Radius Main and Connecting Rod Fillet Radius ‪

    3.5 mm (0.1378 in.) ‪

    4.0 mm (0.1575 in.) ‪

    - ‪

    Surface Finish - Main and Connecting Rod Journals ‪

    - ‪

    0.3 m 12 AA ‪

    0.3 m 12 AA ‪

    Surface Finish - Thrust Wall ‪

    - ‪

    0.4 m 16 AA ‪

    0.4 m 16 AA ‪

    Surface Finish - Oil Seal Area ‪

    0 ‪

    2.0 m 80 AA ‪

    2.0 m 80 AA ‪

    Journal Hardness (Rockwell C) ‪

    47 Rc ‪

    55 Rc ‪

    8 Rc ‪

    Crankshaft Dynamic Balance - (Ounce - Inch) ‪

    - ‪

    1.5 ‪

    1.5 ‪

    Main and Connecting Rod Journal Alignment Per Length of Pin ‪

    - ‪

    0.012 mm (0.0004 in.) ‪

    - ‪

    Crankshaft - Convex ‪

    - ‪

    0.013 mm (0.0005 in.) ‪

    0.043 mm (0.0017 in.) ‪

    Butt Face Concave ‪

    - ‪

    0.03 mm (0.0011 in.) ‪

    0.043 mm (0.0017 in.) ‪

    Pin Width ‪

    55.77 mm (2.196 in.) ‪

    56.07 mm (2.208 in.) ‪

    0.30 mm (0.012 in.) ‪

    Timing Gear Diameter (must maintain 0.003 -0.005 in. press fit) ‪

    133.67 (5.263 in.) ‪

    133.70 mm (5.264 in.) ‪

    0.030 mm (0.0012 in.) ‪

    Series 60 Crankshaft Remanufacturing Tolerances
  12. Journal O.D. score marks must be:
    1. Circumferential-not axial.
    2. Maximum of 0.254 mm (0.010 in.) wide.
    3. At least 3.175 mm (0.125 in.) from fillet tangent point.
    4. Smooth, no proud metal.
    5. Maximum of one mark per journal.
  13. No journal dimpling permitted for removal of defects.
  14. Nicks, dents or pits in journal O.D. must be 3.175 mm (0.125 in.) maximum diameter, no proud metal, maximum (3) per journal.
  15. Pins and bearing journals which exhibit discoloration due to excessive overheating from bearing failure are not acceptable for rework.
  16. If one or more main or connecting rod journals require grinding, then grind all of the main journals or all of the connecting rod journals to the same required size.
  17. Inspect the hardness of all journals. Crankshafts to be 47-55 Rc.
  18. Clean the crankshaft as follows:
    1. Clean all oil passages with a brush. Power probing is recommended.
    2. Remove all copper, brass and lead, etc., from journal surfaces. Scrub the crankshaft until clean in a detergent bath.
    3. Extremely rusted shafts can be soaked in hot rust stripper.
    4. Scrub all webs and counterweights with a wire brush to remove all blackened residue. Use industrial detergent at proper ratios or regular hot degreaser.
    5. NOTICE:

      A crack in any vital area of the crankshaft cannot be repaired or removed. That is why magnetic particle inspection of the entire crankshaft before regrinding is mandatory. Crankshafts that are cracked MUST BE SCRAPPED. ‪

  19. After a visual inspection, the crankshaft should be magnetically inspected using one of the two following methods:
    1. Magnetic Particle Method: Refer to section .
    2. Fluorescent Magnetic Particle Method: Refer to section .

MACHINING OPERATIONS

The following topics cover machining operations: ‪

Main and Connecting Rod Journals: ‪

  1. Connecting rod and main bearing journal grinding should be performed with crankshaft rotation opposite to actual engine rotation. See Figure 20326 .

    Note: Crankshaft and main journal grinding should be performed with crankshaft rotation opposite to actual engine rotation. While polishing should be performed with the crankshaft rotation in the same direction as engine rotation.

    Crankshaft Grinding Rotation

  2. Crankshaft polishing should be performed with the crankshaft rotation in the same direction as engine rotation.
  3. All connecting rod journal fillets must have a 5.75 mm (0.226 in.) radius between the crank cheek and the journal.
  4. All connecting rod journal fillets must have a 5.75 mm (0.226 in.) radius between the crank cheek and the journal. All main journal fillets must have a 3.75 mm (0.148 in.) radius between the crank cheek and the journal.
  5. No journal may have any sharp grind marks. The fillet must blend smoothly into the journal and the crank cheek and must be free of scratches.
  6. The radius may be checked with a fillet gage. See Figure 20327 .

    Crankshaft Journal Fillets

  7. Lobing and Chatter: The number of lobes around the journal circumference, times the average peak to valley lobe height in micrometers, shall not exceed 42 micrometers. Peak to valley excursions exceeding 1.0 micrometers shall be considered lobing or chatter.
  8. Excursions can be measured on a circular chart of the circumferential profile.

Perform the following steps for grinding connection rod journals: ‪

  1. Grind the pin O.D. surface to the specified undersize. The undersize conditions are 0.254 mm, 0.508 mm or 0.762 mm (approximately 0.010 in., 0.020 in. or 0.030 in.).
  2. ALL connecting rod journals must be ground to the same undersize condition.
  3. Journal taper on a radial basis shall not exceed 0.008 mm (0.0003 in.) overall, or exceed 0.004 mm (0.00016 in.) on half-length.

    Note: Avoid localized heating, which often produces grinding cracks. Cool the crankshaft generously with coolant while grinding. Do not crowd the grinding wheel into the work.

  4. Grind sidewalls wide enough to clean up the basic face surface, not to exceed pin width allowable. See Figure 20325 .
  5. If there are deep interruptions, gouges or nicks that do not extend into fillets, smooth the edges with 120 grit emery cloth.

Perform the following steps for grinding main bearing journals: ‪

  1. Grind the main bearing O.D. surface to the specified undersize. The undersize conditions are 0.254, 0.508 or 0.762 mm (approximately 0.010, 0.020, or 0.030 in.).

    Note: Avoid localized heating, which often produces grinding cracks. Cool the crankshaft generously with coolant while grinding. Do not crowd the grinding wheel into the work.

  2. ALL main bearing journals must be ground to the same undersize conditions.
  3. Journal taper on a radial basis shall not exceed 0.012 (0.0005 in.) overall or exceed 0.006 mm (0.00024 in.) on half-length.

Perform the following steps for other machining operations: ‪

  1. Examine the thrust wall (No. 4 main bearing):
    1. If the thrust wall surface is scored, scratched or groove worn, the thrust wall must be "bump ground."
    2. The maximum run-out of the thrust wall is 0.038 mm (0.0015 in.) TIR.
    3. If wear is 0.0508 mm (0.002 in.) or more, regrind to restore flatness to the thrust wall. See Figure 20328 .
    4. No. 6 Main Journal Thrust Wall Dimensions

    5. An oversize thrust wall is to be "bump ground" in multiples of 0.127 mm (0.005 in.), with a maximum of 0.250 mm (0.010 in.) to be removed from each side. Record oversize for installations.
    6. Note: Avoid localized heating, which often produces grinding cracks. Cool the crankshaft generously with coolant while grinding. Do not crowd the grinding wheel into the work.

  2. Chamfer all oil holes to remove grinding burrs to the limit shown on illustrations. See Figure 20329 . See Figure 20330 . See Figure 20331 . See Figure 20600 .

    Oil Hole Specifications - Connecting Rod Journals - 11.1 L Crankshaft (139 mm stroke)

    Oil Hole Specifications - Connecting Rod Journals - 12.7 L Crankshaft (160 mm stroke)

    Connecting Rod Journal Oil Hole Chamfer Limits

    Main Journal Oil Hole Chamfer Limits

  3. Repair the flywheel and pulley contact faces of the crankshaft to clean up the surface of any nicks, gouges or raised metal. The crankshaft face must be 0.013 mm (0.0005 in.) convex to 0.025 mm (0.001 in.) concave.

Perform the following steps for after grinding: ‪

  1. Inspect the crankshaft by the magnetic particle method after grinding has been completed to determine whether the grinding operation has produced cracks.
  2. Re-tap and check all internal threads with plug gages to determine acceptability. If necessary, heli-coil pulley and flywheel flange bolt holes with the following restrictions: Heli-coil 2 holes maximum per crankshaft end (front or rear). Heli-coil of two adjacent holes at rear (forward end) is not permitted.
  3. Demagnetize the crankshaft.
  4. Clean the crankshaft and oil passages thoroughly with clean fuel oil.

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  5. Dry the crankshaft with compressed air.

GLOSSARY

The following glossary terms support the Series 60 Engine. ‪

AA - ARITHMETICAL AVERAGE: The average total sum of the heights and depths of the ridges and valleys above and below the mean reference line. Limits for journal surfaces are 0.3 m (12 AA). ‪

AXIAL PROFILE: The deviation of the journal surface from a reference line. Total peak to valley variation per full length of journal. ‪

AXIAL PROFILE SLOPE: The amount of variation tolerable from the mean reference line of the journal in a particular distance (example: 0.0025 mm [0.0001 in.] deviation / 2.54 mm [0.100 in.] length maximum). This specification indicates that any deviation in excess of 0.0025 mm (0.0001 in.) inside a 2.54 mm (0.100 in.) length is not acceptable. ‪

GOULD 1200: Surfanalyzer 1200 surface texture measuring system is used to determine surface parameters such as profile, roundness and waviness. A diamond stylus having a radius of 0.0025-0.013 mm (0.0001 -0.0005 in.) is moved at a constant speed over the surface. Vertical displacements of this stylus are converted into a voltage signal through a linear variable differential transformer. ‪

OIL HOLE WASHOUT: The localized removal of material below the reference surface of an idealized round and straight journal at the trailing edge of the oil hole. This condition is the result of excessive polishing with a soft black apparatus (nut cracker, soft show, rawhide) with lapping paper or cloth in an attempt to improve the surface finish. ‪

A depression (washout) extending beyond the oil hole blend out ellipse reduces the effective bearing area appreciably. This type of polishing is not recommended. ‪

PIN and CRANKPIN: The cylindrical piece to which the connecting rod is attached. ‪

RADIAL CHATTER: This term relates to surface irregularities which are of greater magnitude or spacing than those indicated by the term roughness. Chatter might be the result of vibration or deflection of a cutting tool, of some part of the machine, or the work itself. ‪

ENGINE PLUG AND DOWEL CHARTS

Following figures support the Series 60 Engine plugs and dowels. ‪

See Figure 20855 ; see Figure 20856 ; see Figure 20332 ; see Figure 20857 ; see Figure 20858 ; and see Figure 20333 for plug and dowel information supporting 1991 model year and later Series 60 Engines. ‪

1. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14 -18 lbft). ‪

6. 8929163 Dowel (Diamond) * ‪

2. 8929015 Dowel (Round) * ‪

7. 5139991 Cup Plug (5 places) ‪

3. 8929594 3/8 in. Pipe Plug (2 places). Torque to 24-31 Nm (18-23 lbft). ‪

8. 8929152 Dowel (Round) * ‪

4. 8924140 Draincock ‪

9. 8922327 1/4 in. Pipe Plug (1 place). Opposite Oil Level Dipstick Location. ‪

5. 8929022 Dowel (Diamond) (2 places)* ‪

10. 8929594 3/8 in. Pipe Plug (2 places). Torque to 24-31 Nm (18-23 lbft). ‪

*Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.). ‪

Use tool J 36244-1 to install. ‪

Use tool J 36224-2 to install. ‪

Refer to illustration for orientation of dowels. ‪

Cup plug 7 are installed 2.5-3.0 mm (0.098 in. -0.118 in.) below the machined surface. Use tool set J 35653 to install the cup plugs. Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite 620 (or equivalent) before installing. ‪

Right Side View

1. 8929022 Dowel (Diamond) (2 places)* ‪

5. 8923916 1/2 in. Pipe Plug (1 place). Torque to 31-39 Nm (23-29 lbft). ‪

2. 8924517 3/8 in. Pipe Plug (2 places). Torque to 24-31 Nm (18-23 lbft). ‪

6. 8929163 Dowel (Diamond) * ‪

3. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14 -18 lbft). ‪

7. 8922327 1/4 in. Pipe Plug (2 places). Required only for pressure testing of cylinder block. In service, these plugs are replaced by the oil pressure sensor (OPS), refer to section , and the oil temperature sensor (OTS), refer to section . ‪

4. 8929152 Dowel (Round) * ‪

8. 8929015 Dowel (Round) * ‪

*Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.). ‪

Use tool J 36244 to install. ‪

Use tool J 36244-2 to install. ‪

Refer to illustration for orientation of dowels. ‪

Left Side View

Cylinder Head Deck

Front View

No. 6 Main Bearing Cap

1.8929022 Dowel (Diamond-2 Places) ‪

3.8929015 Dowel (Round) ‪

2.5139988 Cup Plug (2 Places) ‪

Rear View

See Figure 20859 ; see Figure 20860 ; see Figure 20334 ; see Figure 20861 ; see Figure 20862 ; see Figure 20333 ; see Figure 20336 ; see Figure 20337 ; and see Figure 20338 for plug and dowel information supporting pre-1991 model year Series 60 Engines. ‪

1. 5139991 Cup Plug (6 places) ‪

6. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14-18 lbft). ‪

2. 8929015 Dowel (Round) * ‪

7. 8923312 3/4 in. Pipe Plug (1 place). Torque to 45-56 Nm (31-39 lbft). ‪

3. 8929022 Dowel (Diamond) (2 places)* ‪

8. 8929152 Dowel (Round) * ‪

4. 8929153 Dowel (Diamond) ‪

9. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14-18 lbft). ‪

5. 8924140 Draincock ‪

10. 8929594 3/8 in. Pipe Plug (2 places). Torque to 24-31 Nm (18-23 lbft). ‪

*Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.). ‪

Use tool J 36244-1 to install. ‪

Use tool J 36244-2 to install. ‪

Refer to illustration for orientation of dowels. ‪

Cup plug 7 are installed 2.5-3.0 mm (0.098 -0.118 in.) below the machined surface. Use tool set J 35653 to install the cup plugs. Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite 620 (or equivalent) before installing. ‪

Right Side View

1. 8929022 Dowel (Diamond) (2 places)* ‪

5. 8923916 1/2 in. Pipe Plug (1 place). Torque to 31-39 Nm (23-29 lbft). ‪

2. 8929594 3/8 in. Pipe Plug (2 places) Torque to 24-31 Nm (18-23 lbft). ‪

6. 8929153 Dowel (Diamond) * ‪

3. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14-18 lbft). ‪

7. 8922327 1/4 in. Pipe Plug (2 places). Required only for pressure testing of cylinder block. In service, these plugs are replaced by the oil pressure sensor (OPS). ‪

4. 8929152 Dowel (Round) * ‪

8. 8929015 Dowel (Round) * ‪

*Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.) ‪

Use toolJ 36224-1 to install. ‪

Use tool J 36224-2 to install. ‪

Refer to illustration for orientation of dowels. ‪

Left Side View

1. 8929163 Dowel (Diamond) ‪

3. 5151272 Plug (1.0 mm [0.040 in.] below surface) ‪

2. 8929152 Dowel ‪

Cylinder Head Deck

1. 8929022 Dowel (Diamond-2 Places) ‪

3. 5139988 Cup Plug (2 Places) ‪

2. 8920062 Dowel Pin ‪

4. Bull Gear Pilot Bore ‪

Front View

No. 6 Main Bearing Cap

1. 8929022 Dowel (Diamond-2 Places) ‪

3. 8929015 Dowel (Round) ‪

2. 5139988 Cup Plug (2 Places) ‪

Rear View

1. 5138638 Dowel (Hollow) (7 places). Install to a height of 5.000 mm 0.254 mm (0.197 in. 0.010 in.). Bearing Cap ‪

4. Cylinder Head Dowel ‪

2. Rocker Arm Shaft ‪

5. Cylinder Head ‪

3. Camshaft Cap ‪

6. 5143033 Dowel (Diamond) (3 places). Install to a height of 6.1 mm 0.5 mm (0.240 in. 0.010 in.) ‪

Cylinder Head Dowel Chart

1. 5109157 Cup Plug (11 places) * ‪

5. 8926991 Fuse Plug. Torque to 19-24 Nm (14-18 lbft). ‪

2. 5139991 Cup Plug (2 places) * ‪

6. 8923313 3/4 in. Pipe Plug (2 places). Torque to 45-56 Nm (33-41 lbft). ‪

3. 23513197 3/8 in. Pipe Plug (Square Drive) (2 places). Torque to 30-33 Nm (22-24 lbft). ‪

7. 8924750 1 in. Pipe Plug (1 place). Torque to 102-127 Nm (75-94 lbft). ‪

4. 8923916 1/2 in. Pipe Plug (2 places). Torque to 31-39 Nm (23-29 lbft). ‪

*Cup plugs 1 and 2 are installed 2.5-3.0 mm (0.098 in. -0.118 in.) below the machined surface. ‪

Use tool set J 35653 to install the cup plugs. Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite 620 (or equivalent) before installing. ‪

Cylinder Head Cup, Pipe Plug, and Dowel Chart

Gear Case Dowel Chart

SPECIFICATIONS

Specifications, clearances and wear limits are listed below. It should be specifically noted that the clearances apply only when all new parts are used at the point where the various specifications apply. This also applies to references within the text of the manual. The column entitled "Limits" in this chart lists the amount of wear or increase of clearance which can be tolerated in used engine parts and still ensure satisfactory performance. It should be emphasized that the figures given as "Limits" must be qualified by the judgment of personnel responsible for installing new parts. These wear limits are, in general, listed only for the parts more frequently replaced in engine overhaul work. For additional information, refer to the text. ‪

These limits also apply to oversize and undersize parts. ‪

Refer to the following tables to obtain specifications, new clearances, and wear limits for the Series 60 Engine: ‪

  1. Cylinder block is listed in Table .
  2. Cylinder liner is listed in Table .
  3. Cross-head piston and piston rings are listed in Table .
  4. Articulated 14L piston and piston rings are listed in Table .
  5. Cross-head cast-iron piston pin is listed in Table .
  6. Articulated 14L piston pin is listed in Table .
  7. Crankshaft is listed in Table .
  8. Connecting rod bearing is listed in Table .
  9. Closed-end connecting rod bushing is listed in Table .
  10. Main bearing is listed in Table .
  11. Camshaft is listed in Table .
  12. Camshaft bearing is listed in Table .
  13. Camshaft drive gear is listed in Table .
  14. Idler gear is listed in Table .
  15. Crankshaft timing gear is listed in Table .
  16. Bull gear is listed in Table .
  17. Cylinder head is listed in Table .
  18. Intake valve (diesel) seat insert is listed in Table .
  19. Intake valve (natural gas) seat insert is listed in Table .
  20. Exhaust valve (diesel) seat insert is listed in Table .
  21. Exhaust valve (natural gas) seat insert is listed in Table .
  22. Intake valves (diesel) are listed in Table .
  23. Intake valves (natural gas) are listed in Table .
  24. Exhaust valves (diesel) are listed in Table .
  25. Exhaust valves (natural gas) are listed in Table .
  26. Valve guides (diesel) are listed in Table .
  27. Valve guides (natural gas) are listed in Table .
  28. Rocker arms and shaft (diesel) are listed in Table .
  29. Rocker arms and shaft (natural gas) are listed in Table .
  30. Cam follower roller is listed in Table .
  31. Exceptions to standard fastener torque specifications are listed in Table .
  32. Series 60 Diesel valve lash, Jake Brake lash and camshaft timing specifications are listed in Tables , and .
  33. Series 60 Gas valve lash and camshaft timing specifications are listed in Table .

Engine Part (Standard Size, New)

Minimum

Maximum

Limits

Block Bore: Diameter - 15.0 mm (0.59 in.) from top of block ‪

149.050 mm (5.868 in.) ‪

149.120 mm (5.871 in.) ‪

- ‪

Diameter - 235.0 mm (9.25 in.) from top of block ‪

146.050 mm (5.750 in.) ‪

146.125 mm (5.753 in.) ‪

0.076 mm (0.003 in.) ‪